13.
Connect the PDM and connect the ground strap
to lift truck frame and attach it to battery.
14.
Install battery and battery tray. See Figure 23.
15.
Install LPG tank and bracket on lift truck. See
Fuel System PSI 2.4L
0900YRM1757 for the pro-
cedures.
16.
Install the rear side covers, floor plates, and hood
and seat combination. See section Hood, Seat,
and Side Covers Replacement for the proce-
dures.
17.
If removed, install overhead guard. See section
Overhead Guard Replacement for procedures.
18.
Check all fluid levels and fill as needed. See
Peri-
odic Maintenance
8000YRM1774 for quantities
and procedures.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
19.
Empty drain pan contents.
20.
Swing LPG tank into position on back of counter-
weight and open shutoff valve on tank.
Diesel Engine
WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The
engine can weight approximately 194 kg (428 lb).
CAUTION
Keep the engine level when installing the engine
to the transmission so the drive plate is not dam-
aged.
1.
Install torque converter in torque converter hous-
ing.
2.
Connect lifting device to engine and lift engine
into frame. Install engine adapter to transmission
bolts, if equipped.
3.
Install isolators, capscrews, washers, snubbing
washers, and flange locknuts on engine mounts.
See Figure 35. Tighten flange locknuts to
150 N•m (110 lbf ft).
4.
Use access port on side of engine and install four
bolts attached flywheel to torque converter. See
Figure 33. Tighten bolts to 55 N•m (41 lbf ft).
5.
Install six hex head capscrews and six lockwash-
ers on flywheel housing and torque converter
housing on torque converter housing side. See
Figure
Tighten
capscrews
to
38 N•m (28 lbf ft).
6.
Install four flange bolts on flywheel housing and
torque converter housing on transmission side.
See
Tighten
capscrews
to
38 N•m (28 lbf ft).
7.
Connect engine wiring harness connectors to
transmission, temperature sensor connector, sol-
enoid valve connector, transducer connectors,
and proportional valve connectors. See Figure 32.
8.
Connect engine wiring harness connectors to
chassis harness connectors. See Figure 29.
WARNING
All fuels are very flammable and can burn or
cause an explosion. DO NOT use an open flame to
check the fuel lever or to check for leaks in the
fuel system.
No smoking.
Breathing fuel vapor may cause nausea, uncon-
sciousness, or death. Long term exposure to gas-
oline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
9.
Remove caps from fuel lines and connect lines at
engine. See Figure 30.
10.
Install radiator shroud, fan pulley, and fan assem-
bly. See Figure 30. See
Cooling System - PSI
2.4L Engine
0700YRM1767 for the installation
procedures.
11.
Connect coolant hoses and lines to transmission.
Fill cooling system with a mixture specified in
Pe-
riodic Maintenance
8000YRM1774.
12.
Install battery tray and battery as described in the
steps below:
a.
Install battery tray and three capscrews on
frame. See Figure 31.
b.
Install battery in battery tray. See Figure 31.
0100 YRM 1766
Engine Replacement
37
